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Clay calcination

FCB Flash calciner

Reducing the cement industry’s carbon footprint

Calcined clay is widely recognized as a sustainable substitute for cement clinker in the production of cementing materials. Reducing clinker use by 50% and replacing it with calcined clay has no impact on the final concrete resistance, but offers a 40% reduction in CO2.

Fives’ FCB Flash Calciner is a comprehensive clay calcining solution that helps our clients meet both production and environmental goals. Committed to driving innovation for a more sustainable cement industry, we are proud to offer cost-effective and environmentally friendly equipment.

Flexible and reliable calcination of a wide range of materials

Our FCB Flash Calciner can be used with a wide range of clay materials. Its advanced technology prevents the raw materials from overheating. This is essential for producing highly amorphous pozzolan (an alternative cementing material) through calcination of kaolin or of clays containing kaolinite.

The equipment offers emissions reduction along with many other benefits:

  • High flexibility due to exceptionally fast warm-up
  • Stable temperature control
  • Accurate control of kaolinite dehydroxylation
  • Highly activated clay
  • Low energy consumption through heat recovery
  • Variable capacity
  • Outstanding end product with high consistency and low attrition
  • Lower maintenance needs
  • Compact footprint
  • Low CAPEX for new plants
  • Simplified management thanks to its state-of-the-art automation system

A complete turnkey solution for high-capacity plants

Drying and grinding raw material

  • Crushed material (<50 mm / <2 in) is ground with a dedicated mill and classifier for increased fineness (<100 μm)
  • Raw materials are dried using hot gases
  • Once the dried material has achieved <0.5% humidity, it is conveyed to the top of the preheater

Preheating and calcining

  • The FCB Cyclone provides two stages of preheating and one stage of calcining
  • A calcination chamber or the FCB Flash Calciner offers two different firing options:
    • Indirect firing: optimum temperature control and possible use of alternative fuels
    • Direct firing: very simple to install and use, but limited options for alternative fuel use

Cooling

High-efficiency cyclones offer a two-stage cooling process, featuring:

  • Low pressure drop
  • Slope at inlet to avoid build-up
  • Large cone outlet for smooth material flow
  • Upper cyclones designed to boost efficiency
  • Heat recovery
  • Color control through a reduction of iron oxides